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Transfer Clutch: Assembly

WARNING: This page is about a different variant/trim than selected.
  1. Install the snap ring.
    NOTE: Make the openings deviated by 180°.
    G13951213Courtesy of SUBARU OF AMERICA, INC.
  2. Using the ST and a press, press-fit the transfer drive gear.

    Preparation tool: 

    ST: INSTALLER (398177700)

    G13951214Courtesy of SUBARU OF AMERICA, INC.
  3. Install the snap ring.
    G13951215Courtesy of SUBARU OF AMERICA, INC.
  4. Install a new O-ring.
    NOTE: Apply CVTF to the O-rings.
    G13951216Courtesy of SUBARU OF AMERICA, INC.
  5. Install the oil separate pipe and oil pipe.
    NOTE: Apply CVTF to the oil separate pipe.
    G13951217Courtesy of SUBARU OF AMERICA, INC.
  6. Press-fit the reduction drive gear shaft using the ST and a press.

    Preparation tool: 

    ST: BUSHING 1-2 INSTALLER (499277100)

    G13951218Courtesy of SUBARU OF AMERICA, INC.
  7. Install the transfer clutch piston, return spring and transfer clutch piston seal.
    NOTE: Apply CVTF to the seal section of transfer clutch piston.
    G13951219Courtesy of SUBARU OF AMERICA, INC.
  8. Compress the return spring using the ST1, ST2 and a press to install the snap ring.

    Preparation tool: 

    ST1: COMPRESSOR SPECIAL TOOL (18762AA001)

    ST2: INSTALLER (18657AA000)

    G13951220Courtesy of SUBARU OF AMERICA, INC.
  9. Blow compressed air through the hole shown in the figure, and check the transfer clutch piston operation.
    G13951221Courtesy of SUBARU OF AMERICA, INC.
  10. Select the transfer clutch plate set and pressure plate (rear side).
    NOTE: The pressure plate (front side) is included in the transfer clutch plate set.
    1. Set the pressure plate (rear side) and transfer clutch plate set to the reduction drive gear shaft, and then install the snap ring.
      NOTE: Face the smooth side of the pressure plate (rear side) toward the transfer clutch plate set.
      G13951222Courtesy of SUBARU OF AMERICA, INC.
    2. Set the shim, etc. (A) between the snap ring and pressure plate (front side) so that each plate does not tilt.
      G13951223Courtesy of SUBARU OF AMERICA, INC.
    3. Measure the clearance "C" between snap ring and pressure plate (front side) using a thickness gauge.

      Service limit: 

      1.6 mm (0.06 in)

      G13951224Courtesy of SUBARU OF AMERICA, INC.
    4. If the value exceeds the limit, perform the following procedures.
      1. Measure the thickness of the pressure plate (front side) and pressure plate (rear side).
      2. Replace with a new transfer clutch plate set that includes a pressure plate (front side) whose thickness is close to the measured thickness of pressure plate (front side), and perform measurement from step (2) again.
      3. If it exceeds the initial standard value, adjust the thickness of pressure plate (rear side) so that the value falls within the initial standard.

        Initial standard: 

        0.7 - 1.1 mm (0.03 - 0.04 in)

  11. Using the ST and a press, press-fit a new ball bearing.
    NOTE: Apply CVTF to the press-fitting area.

    Preparation tool: 

    ST: BUSHING 1-2 INSTALLER (499277100)

G13951225Courtesy of SUBARU OF AMERICA, INC.
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